Recycable plastic pallet

ABSTRACT

A pallet ( 10 ) comprises a plurality of members ( 12 ) made from plastics material. The members ( 12 ) are divided into a set of planks ( 12 A) and a set of beams ( 12 B). The planks ( 12 A) are arranged into two groups, the first group ( 12 A 1 ) which lie on one side of the pallet ( 10 ) and the second group ( 12 A 2 ) which lie on an opposite side of the pallet ( 10 ) with the beams ( 12 B) lying therebetween. The planks ( 12 A 1 ) and ( 12 A 2 ) are arranged in parallel planes and extend in the same direction to each other, and transversely of the beams ( 12 B). Pins ( 16 ) are driven through holes ( 14 A) and ( 14 B) formed in the planks ( 12 A) and the beams ( 12 B) respectively for coupling the planks ( 12 A) to the beams ( 12 B) to form pallet ( 10 ).

FIELD OF THE INVENTION

The present invention relates to a pallet of a type typically used forthe storage, stacking and transport of materials such as bricks, bags ofparticulate or powder materials such as manure, peat, cement; sheetproducts such as roofing or fencing sheets; and the like.

BACKGROUND OF THE INVENTION

For ease of handling and convenience, many materials are stored, stackedor transported on pallets. A typical pallet has a plurality of spacedapart beams extending in one direction with a plurality of transverselyextending slats attached to upper and lower surfaces of the beams. Theslats form a load-bearing surface for the material supported by thepallets.

Pallets are most commonly made of wood. However over the last few yearsthere has been an influx of pallets made of plastics material, somebeing manufactured from recycled materials, others from virgin material.These pallets are manufactured by injection moulding in order to obtainminimum load bearing requirements of the relevant standard, and tomaintain production reproducibility.

Nevertheless, such plastics pallets have two fundamental deficiencies.The first is the inability to handle loads in excess of 1000 kg. Thesecond is that the pallets are non-repairable. With all pallets, be theywood or plastics, an uncontrolled impact can cause damage rendering thepallet unsuitable until repaired. Wooden pallets can be, and are,repaired on a regular basis. The injection moulded plastics pallets arenot and are typically destroyed or recycled thus incurring significantreplacement cost to the user.

SUMMARY OF THE INVENTION

The present invention was developed with a view to providing analternate form of pallet made from plastics material.

According to the present invention there is provided a pallet including:

-   -   a plurality of plastics material members, a first set of said        members extending in a first direction and across a second set        of said members; and,    -   a plurality of mechanical fasteners coupling said first set of        members to said second set of members.

Preferably said first set of members comprises a first group of membersand a second group of members and wherein said second set of members isdisposed between said first and second group of members.

Preferably said first and second group of members extend perpendicularto said second set of members.

Preferably said first and second group of members lie in respectivefirst and second parallel planes, said first and second group of membersare spaced by said second set of members.

Preferably each member of said first set of members is of a first commonfirst shape and configuration, and each member of said second set ofmembers is of a common second shape and configuration different to saidfirst shape and configuration.

Preferably each member of said first set of members has a first planarsurface.

Preferably each member of said first set of members has a secondopposite surface formed with a plurality of parallel grooves extendingin a direction of the length of said members.

Preferably each member of said second members has a generally I-shapedtransverse cross-section, including first and second parallel spacedapart flanges and a web extending centrally between said first andsecond flanges.

Preferably each of said members is provided with a plurality oftransversely extending holes.

Preferably said mechanical fasteners are made of plastics material.

Preferably each fastener comprises a single component which extendsthrough respective registering holes in said first set of members andsaid second set of members to couple said members together.

Preferably each fastener includes a head, a shank extending from saidhead and, a tail at an opposite end of said shank, said holes, head andtail relatively configured so that said head is unable to pass throughsaid holes, and said tail passes through said holes in a first directionbut not in a second opposite direction.

Preferably said holes are formed adjacent each longitudinal edge of eachmember of said set of members, with the holes along a first longitudinaledge staggered relative to the holes along a second longitudinal edge.

Throughout this specification the term “comprising” is used inclusively,in the sense that there may be other features and/or steps included inthe invention not expressly defined or comprehended in the features orsteps subsequently defined or described. What such other features and/orsteps may include will be apparent from the specification read as awhole.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the present invention will now be described by way ofexample only with reference to the accompanying drawings in which:

FIG. 1 is a plan view of an embodiment of a pallet made in accordancewith the present invention;

FIG. 2 is a side view of the pallet depicted in FIG. 1;

FIG. 3 is an end view of the pallet depicted in FIG. 1;

FIG. 4 is a view of Section A-A of the pallet depicted in FIG. 1;

FIG. 5 is an enlarged end view of one type of member incorporated in thepallet;

FIG. 6 is an end view of a second type of member incorporated in thepallet; and,

FIG. 7 is a plan view of a fastener incorporated in the pallet.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

With reference to the accompanying drawings and in particular FIGS. 1-4and 7, an embodiment of a pallet 10 in accordance with this inventioncomprises a plurality of plastics material members 12 which are dividedinto two sets, a first set 12A each of which extend in one and the samedirection and a second set of members 12B that extend across the firstset 12A. A plurality of mechanical fasteners in the form of pins 16couple the first set 12A of members to the second set 12B.

The first set 12A of members is arranged into two groups, the firstgroup 12A1 lie on one side of the pallet 10 and a second group 12A2 lieon an opposite side of the pallet, the groups 12A1 and 12A2 beingseparated by the second set 12B of members. More particularly, the firstset 12A of members extend perpendicular to the second set 12B, with thefirst group 12A1 lying in a first plane and forming an upper loadbearing surface, and the second group of members 12A2 lying in a secondplane parallel to the first plane, and forming a lower load bearingsurface.

Referring in particular to FIG. 5, each of the members of the first set12A has a common shape and configuration, being in the general form of aplank with a first planar surface 18 and an opposite surface 20 formedwith a plurality of parallel grooves 22 which extend in the direction ofthe length of that member. For convenience each member of the first setof members will hereinafter be referred to as “plank 12A”. The grooves22 are of equal width and evenly spaced by parallel ridges 24. However,as shown in FIG. 5, the ridges 24 adjacent opposite longitudinal edges26 of the planks 12A are formed of half the width of the remainingridges 24.

A plurality of holes 14A is formed in the planks 12A. The holes 14A arelocated to pass from surface 18 to surface 20 through the grooves 22adjacent the edges 26. As is further apparent from FIG. 1, the holes 14Aalong one longitudinal edge 26 of each plank 12A are staggered relativeto the holes 14A along that plank's opposite longitudinal edge 26. Eachhole 14A has a first portion 15 of a constant diameter and a secondcontiguous portion 17 of constant but smaller diameter.

Each of the members of the set of members 12B has a generally I-shapedtransverse cross-section, comprising first and second parallel flanges28 which are spaced by a centrally located web 30. For convenience themembers of the set 12B will be hereinafter referred to as “beams 12B”.Holes 14B are formed in the beams 12B on both of the flanges 28 and, foreach flange 28 on opposite sides of the web 30. The holes 14B whichextend transversely through the beams 12B are of a constant diameter fortheir entire length. A longitudinally extending semi-circular groove 32is formed centrally along each flange 28 opposite the web 30 toeffectively manage the material flow and cooling consistency duringmanufacture of the beams 12B particularly when made by an extrusionprocess.

Referring to FIG. 7, each pin 16 is formed as a single unitary elementhaving one end 34 in the shape of a disc, a shank 36 extending from end34 and an opposite snap lock end 38. The shank 36 is formed with a firstportion 40 of a first constant diameter and a co-axial portion 42 of aconstant but smaller diameter. A transition portion 44 of short axiallength is provided between the portions 40 and 42. The transitionportion 44 initially tapers in width toward the portion 42 but at apoint 46 approximately half-way between the diameter of portion 40 andthe diameter of portion 42, there is a stepped reduction in the diameterof portion 44. The end 38 is formed with a shoulder 48 adjacent theportion 42 and progressively reduces in outer diameter away from the end34 finally terminating in a chamfered tip 50. The shoulder 48 has alarger diameter than hole portion 17 and hole 14B but is able to passthrough by virtue of inherent resilience of the hole portion 17, hole14B and/or the pin 16. When the shoulder 48 passes through hole 14B itsnap locks on a side of the flange 28 opposite end 34.

The embodiment of the pallet 10 depicted in the accompanying drawingsmay be constructed as follows. Each of the planks 12A and beams 12B canbe extruded from virgin or recycled plastics material. The pin 16 mayalso be formed from plastics material as extruded cylindrical rods whichare then machined to the appropriate shape and configuration. Threebeams 12B are placed on a surface evenly spaced apart and parallel toeach other. Next, three planks 12A2 making up the lower load bearingsurface are placed transversely across the beams 12B with two of theplanks 12A2 extending along opposite edges of the pallet 10 while theremaining plank 12A extends centrally therebetween. With the holes 14Aand 14B in the planks 12A2 and beams 12B in registration, respectivepins 16 are driven through the planks 12A2 into the beams 12B with end38 first. The pins 16 and holes 14A and 14B are relatively configured toprovide a snug interference fit with the end 34 located in thecounter-sunk portion 15, and the shoulder 48 and end 38 located on theside of each flange 28 opposite the planks 12A2. The end 38 is unable topass back through hole 14B due to shoulder 48. With the three planks12A2 fastened to the beams 12B, the ensemble is turned over and theplanks 12A1 forming the upper load bearing surface placed at appropriatelocations along the bearers 12B and fastened by the pins 16, to form afinished or complete pallet 10.

The pallet 10 is used in an identical manner to traditional woodenpallets. In the event of the breakage of a plank 12A, the plank 12A canbe completely removed from the pallet by “drilling out” the pins 16attaching that plank 12A to the beams 12B replacing the broken plankwith a fresh plank and then attaching that plank with the use of furtherpins 16. In an alternate method for removing a broken plank 12A, it maybe possible to shear the pins 16 by applying a transverse impact ontothe ends 38 for example by use of a hammer or with a chisel and hammer.

Now that an embodiment of the pallet 10 has been described in detail itwill be apparent to those skilled in the relevant arts that numerousmodifications and variations may be made without departing from thebasic inventive concepts. For example, in the illustrated pallet 10, theplanks 12A and beams 12B are of different shape and configuration.However this need not necessarily be the case. For example, the planksand beams may have an identical shape and configuration, such as in theform of a rectangular tube having parallel wide sides and parallelnarrow sides, with the planks lying on their wide sides and the beamslying on their narrow sides. The number of planks forming each of theupper and lower surfaces of the pallet 10 may be varied as can be thenumber of beams, although it is envisaged that for a pallet 10 of a sizethe same as the commonly available wooden pallets, three beams would bea desired minimum. For smaller pallets, two beams may be sufficient. Forlarger pallets more than three beams may be desirable. In addition, forlarger pallets diagonally extending beams may also be included. Theshape and configuration of the pins 16 may also be varied. The onlyrequirement of the pins 16 is that they fasten the planks to the beams.Fasteners of a different shape and construction to the pins 16 may beused including multi-component fasteners to achieve the same effect asthe pins 16. It is envisaged that the planks 12A, beams 12B and pins 16will all be made via an extrusion process from common grades of HDPE.However it should be recognised that the components may be made from anynumber of available plastic resins, either individually or incombination and from virgin or recycled materials. The pins 16 may bemade from different materials from the planks 12A and beams 12B. Talcfilled, or glass fibre reinforced resin are considered particularlysuitable to ensure sheer strength of the pin 16 is in excess of thatanticipated during service.

All such modifications and variations together with others that would beobvious to persons skilled in the relevant art are deemed to be withinthe scope of the present invention the nature of which is to bedetermined from the above description and appended claims.

1. A pallet including: a plurality of plastics material members, a firstset of said members extending in a first direction and across a secondset of said members; and, a plurality of mechanical fasteners couplingsaid first set of members to said second set of members.
 2. A palletaccording to claim 1 wherein said first set of members comprises a firstgroup of members and a second group of members and wherein said secondset of members is disposed between said first and second group ofmembers.
 3. A pallet according to claim 2 wherein said first and secondgroup of members extend perpendicular to said second set of members. 4.A pallet according to claim 2 wherein said first and second group ofmembers lie in respective first and second parallel planes, said firstand second group of members are spaced by said second set of members. 5.A pallet according to claim 1 wherein each member of said first set ofmembers is of a first common first shape and configuration, and eachmember of said second set of members is of a common second shape andconfiguration different to said first shape and configuration.
 6. Apallet according to claim 1 wherein each member of said first set ofmembers has a first planar surface.
 7. A pallet according to claim 1wherein each member of said first set of members has a second oppositesurface formed with a plurality of parallel grooves extending in adirection of the length of said members.
 8. A pallet according to claim1 wherein each member of said second members has a generally I-shapedtransverse cross-section, comprising first and second parallel spacedapart flanges and a web extending centrally between said first andsecond flanges.
 9. A pallet according to claim 1 wherein each of saidmembers is provided with a plurality of transversely extending holes.10. A pallet according to claim 9 wherein each fastener comprises asingle component which extends through respective registering holes insaid first set of members and said second set of members to couple saidmembers together.
 11. A pallet according to claim 10 wherein eachfastener includes a head, a shank extending from said head and, a tailat an opposite end of said shank, said holes, head and tail relativelyconfigured so that said head is unable to pass through said holes, andsaid tail passes through said holes in a first direction but not in asecond opposite direction.
 12. A pallet according to claim 9 whereinsaid holes are formed adjacent each longitudinal edge of each member ofsaid set of members, with the holes along a first longitudinal edgestaggered relative to the holes along a second longitudinal edge.
 13. Apallet according to claim 12 wherein said mechanical fasteners are madeof plastics material.
 14. A pallet including: a plurality of plasticsmaterial members, a first set of said members extending in a firstdirection and across a second set of said members, each of said membersbeing provided with at least one transversely extending hole; and, aplurality of fasteners coupling said first set of members to said secondset of members, each fastener including a head, a shank extending fromsaid head, and a tail at an opposite end of said shank, wherein saidholes, head and tail are relatively configured so that said head isunable to pass through said holes, and said tail is able to pass throughsaid holes in a first direction, but not in a second opposite direction.15. A pallet according to claim 14 wherein each of said members isprovided with a plurality of transversely extending holes formedadjacent each longitudinal edge of each respective member, with theholes along a first longitudinal edge staggered relative to the holesalong a second longitudinal edge.
 16. A pallet according to claim 15wherein each fastener comprises a single component which extends throughrespective registering holes in said first set of members and saidsecond set of members to couple said members together.
 17. A palletaccording to claim 14 wherein said first set of members comprises afirst group of members and a second group of members and wherein saidsecond set of members is disposed between said first and second group ofmembers.
 18. A pallet according to claim 17 wherein said first andsecond group of members extend perpendicular to said second set ofmembers.
 19. A pallet according to claim 18 wherein said first andsecond group of members lie in respective first and second parallelplanes, said first and second group of members are spaced by said secondset of members.
 20. A pallet according to claim 14 wherein each memberof said first set of members is of a first common first shape andconfiguration, and each member of said second set of members is of acommon second shape and configuration different to said first shape andconfiguration.
 21. A pallet according to claim 20 wherein each member ofsaid first set of members has a first planar surface.
 22. A palletaccording to claim 21 wherein each member of said first set of membershas a second opposite surface formed with a plurality of parallelgrooves extending in a direction of the length of said members.
 23. Apallet according to claim 14 wherein each member of said second membershas a generally I-shaped transverse cross-section, comprising first andsecond parallel spaced apart flanges and a web extending centrallybetween said first and second flanges.
 24. A pallet according to claim14 wherein said fasteners are made of plastics material.